Abstract: A method of both permanently reinforcing and bonding, by means of a physical connection including a fabric or other arrangement of reinforcing fiber, saturated with a curing liquid resin, and building materials to create a composite assembly is disclosed. Once cured, the previously liquid resin, having surrounded the fiber and features of the surfaces of the elements being joined, combines them within a single, shared resin matrix. The resulting composite assembly incorporates a new method of providing reinforcement from within, and can be formed into any of various products or components in the light construction industry, such as window sashes, millwork, and the like.

Abstract: A method is disclosed. The method includes forming a groove in at least one of opposing planar surfaces of a cellular thermoform plastic substrate. The groove is formed at an edge region of the substrate. A stiffener is positioned in the groove, and a fiber matt is laid on the at least one planar surface containing the groove. The stiffener and fiber matt are embedded in a thermoset resin. The thermoset resin is cured to form a fiber reinforced thermoset plastic reinforcement. The substrate is then cross-sectionally cut to form a profile. The profile can be further finished to form a beveled siding for buildings.

Abstract: A method is disclosed. The method includes forming a groove in at least one of opposing planar surfaces of a cellular thermoform plastic substrate. The groove is formed at an edge region of the substrate. A stiffener is positioned in the groove, and a fiber matt is laid on the at least one planar surface containing the groove. The stiffener and fiber matt are embedded in a thermoset resin. The thermoset resin is cured to form a fiber reinforced thermoset plastic reinforcement. The substrate is then cross-sectionally cut to form a profile. The profile can be further finished to form a beveled siding for buildings.

Abstract: A plank is disclosed. The plank has a cellular thermoform plastic substrate, a groove formed in at least one planar surface of the cellular thermoform plastic substrate, and a fiber reinforced thermoset plastic backing on the at least one planar surface. The fiber reinforced thermoset plastic backing includes a fiber chord positioned in the groove, a fiber matt placed upon at least a portion of the one planar surface, and a cured strip thermoset resin on the one planar surface in which the fiber chord and the fiber matt are embedded. Planks for siding of buildings and a method of forming the plank are also disclosed.